Formaldehyde free woven and non-woven fabrics having improved hot wet tensile strength and binder formulations for same

Abstract

Glass mats for use in building construction are provided. The mats include chopped glass fibers and a formaldehyde-free-curable binder disposed on the glass fibers. The binder includes a binder selected from polyorganic acid-polyol, starch grafted acrylic styrene and acrylic modified polyvinyl acetate, for example, containing a sufficient amount of a hydrophobic additive to improve the hot wet retention of the mat after five minutes of exposure to 80° C. water by at least about 5%.

1 . A glass mat for use in building construction applications comprising:
 chopped glass fibers; and   a formaldehyde-free, curable binder disposed on said glass fibers comprising a starch grafted acrylic styrene binder composition containing a sufficient amount of a hydrophobic additive to improve the hot wet retention of said mat by at least about 5% after five minutes of exposure to 80° C. water.   
     
     
         2 . The glass mat of  claim 1  wherein said hydrophobic additive comprises a reactive hydrophobic additive. 
     
     
         3 . The glass mat of  claim 2  wherein said reactive hydrophobic additive comprises one or more of stearylated acrylates, stearyl melamines, polyethylene acrylic acids, emulsified asphalt-based resin, coal tar-based resin, hydrophobic acrylics, maleated PE or PP waxes epoxidized fatty acid based oils, and epoxy silanes. 
     
     
         4 . The glass mat of  claim 2  further comprising a reagent with cross-link polyol functionality. 
     
     
         5 . The glass mat of  claim 1  wherein said starch grafted acrylic styrene binder is added to a target LOI of about 5-35%. 
     
     
         6 . The glass mat of  claim 1  wherein said binder composition, following curing, resists substantial degradation when exposed to molten asphalt in the temperature range of about 150-250° C. 
     
     
         7 . The glass mat of  claim 1  wherein said starch grafted acrylic styrene binder composition has a pH which is neutral to slightly basic. 
     
     
         8 . A roofing shingle comprising an asphalt composition matrix reinforced with a non-woven glass mat and a layer of mineral containing granules adhered to a top surface of said asphalt composition matrix, said non-woven glass mat comprising a formaldehyde-free, curable binder composition including starch grafted acrylic styrene binder comprising a sufficient amount of a hydrophobic additive to improve the hot wet retention of said mat after five minutes of exposure to 80° C. water by at least 5%. 
     
     
         9 . The shingle of  claim 8  wherein said hydrophobic additive comprises a reactive hydrophobic additive which binds to said starch grafted acrylic styrene binder during curing. 
     
     
         10 . The shingle of  claim 8  wherein said hydrophobic additive comprises an organic based additive which provides increased compatibility between the starch grafted acrylic styrene binder and the asphalt composition matrix. 
     
     
         11 . A glass mat for use in building construction applications comprising:
 chopped glass fibers; and   a formaldehyde-free, curable binder disposed on said glass fibers comprising a catalyzed polyorganic acid-polyol binder composition containing a sufficient amount of a hydrophobic additive to improve the hot wet retention of said mat by at least about 5% after five minutes of exposure to 80° C. water.   
     
     
         12 . The glass mat of  claim 11  wherein said hydrophobic additive comprises a reactive hydrophobic additive. 
     
     
         13 . The glass mat of  claim 12  wherein said reactive hydrophobic additive comprises one or more of stearyl acrylates, stearyl melamines, epoxidized fatty acid based oils, and epoxy silanes. 
     
     
         14 . The glass mat of  claim 12  wherein said reactive hydrophobic additive comprises a low pH waterborne stearyl acrylic with added self cross-linking functionality which allows the reactive hydrophobic additive to bond with the polyorganic acid-polyol binder during cure. 
     
     
         15 . The glass mat of  claim 11  wherein said catalyzed polyorganic acid-polyol binder is added to a target LOI of about 5-35%. 
     
     
         16 . The glass mat of  claim 11  wherein said binder composition, following curing, resists substantial degradation when exposed to molten asphalt in the temperature range of about 150-250° C. 
     
     
         17 . The glass mat of  claim 11  wherein said catalyzed polyorganic acid-polyol binder composition is cured at a temperature of about 175-250° C. 
     
     
         18 . A roofing shingle comprising an asphalt composition matrix reinforced with a non-woven glass mat and a layer of mineral containing granules adhered to a top surface of said asphalt composition matrix, said non-woven glass mat comprising a formaldehyde-free, curable binder composition including catalyzed polyorganic acid-polyol binder comprising a sufficient amount of a hydrophobic additive to improve the hot wet retention of said mat after five minutes of exposure to 80° C. water by at least 5%. 
     
     
         19 . The shingle of  claim 18  wherein said hydrophobic additive comprises a reactive hydrophobic additive which binds to said catalyzed polyorganic acid-polyol binder during curing. 
     
     
         20 . The shingle of  claim 18  wherein said non-woven glass mat comprises chopped glass fibers. 
     
     
         21 . The shingle of  claim 18  wherein said hydrophobic additive comprises a low pH waterborne stearyl acrylic with added self cross-linking functionality which allows said low pH waterborne stearyl acrylic to bond with said catalyzed polyorganic acid-polyol during cure. 
     
     
         22 . A method of manufacturing a roofing shingle comprising:
 a) providing a heat-resistant glass mat comprising non-woven glass fibers bonded with a formaldehyde-free, curable binder comprising polyorganic acid polyol binder and a sufficient amount of a hydrophobic additive to improve the hot wet retention by at least about 5%;   b) impregnating said heat resistant glass mat within an asphalt composition in a molten state at a temperature of about 150-250° C.   c) applying mineral containing granules onto a top surface of said asphalt composition; and   d) allowing said asphalt to cool.   
     
     
         23 . The method of  claim 22  wherein said catalyzed polyorganic acid-polyol binder composition is cross-linked in the presence of a catalyst prior to contact with said asphalt in said molten state. 
     
     
         24 . The method of  claim 22  wherein said shingle is substantially formaldehyde-free. 
     
     
         25 . A method of making a glass mat reinforcement suitable for building construction comprising:
 a) disposing chopped glass fibers in an aqueous solution;   b) filtering said aqueous solution from said dispersed chopped glass fibers to form a sheet;   c) drying said sheet;   d) applying a binder to said dried sheet, said binder comprising a formaldehyde-free, curable binder comprising a polyorganic acid-polyol binder composition and a hydrophobic additive; and   e) permitting said binder to cure in the presence of a catalyst at an elevated temperature.   
     
     
         26 . The method of  claim 25  wherein said hydrophobic additive comprises a reactive hydrophobic additive which binds with said polyorganic acid-polyol binder during said curing step (e). 
     
     
         27 . An air filter comprising the glass mat of  claim 1 . 
     
     
         28 . A drywall tape comprising the glass mat of  claim 1 . 
     
     
         29 . A gypsum wallboard comprising a gypsum core bonded to at last one facing comprising the glass mat of  claim 1 . 
     
     
         30 . A heat-resistant glass mat comprising a formaldehyde-free, curable binder including a catalyzed polyorganic acid-polyol binder composition including a sufficient amount of a hydrophobic additive to improve the hot wet retention of said glass mat by at least about 5% when exposed to hot water at a temperature of 80° C. for at least five minutes. 
     
     
         31 . A glass mat for use in building construction applications comprising:
 chopped glass fibers; and   a formaldehyde-free, binder selected from the group consisting of: acrylic polyol, starch grafted acrylic styrene, and acrylic modified polyvinyl acetate, said binder disposed on said glass fibers to bind them together, said binder also comprising a sufficient amount of a hydrophobic additive to improve the hot wet retention of said mat by at least about 5% after 5 minutes of exposure to 80° C. water.   
     
     
         32 . The glass mat of  claim 31  wherein said hydrophobic additive comprises a reactive hydrophobic additive. 
     
     
         33 . The glass mat of  claim 32  wherein said reactive hydrophobic additive comprises one or more of stearyl acrylates, stearyl melamines, epoxidized fatty acid based oils, and epoxy silanes. 
     
     
         34 . A formaldehyde-free, curable binder composition comprising a resinous composition selected from the group consisting of acrylic polyol, starch grafted acrylic styrene, and acrylic modified polyvinyl acetate, and no more than about 10-12% (w/w on dry resin) hydrophobic additive. 
     
     
         35 . The binder of  claim 34  wherein said hydrophobic additive comprises one or more of the group consisting of stearyl acrylates, stearyl melamines, epoxidized fatty acid based oils, and epoxy silanes. 
     
     
         36 . A reinforcing mat comprising:
 glass fibers bonded by a binder composition;   the binder composition including a formaldehyde-free binder cured with a hydrophobic additive to provide bonded glass fibers with a hot wet retention percent of dry tensile strength, in 80° C. water for five minutes duration, at least 5% greater than a hot wet retention percent of dry tensile strength provided by glass fibers bonded by the binder composition without the hydrophobic additive.   
     
     
         37 . The reinforcing mat of  claim 36  wherein the binder comprises styrene acrylate grafted with starch at slightly basic pH to near neutral pH, and wherein the additive comprises, epoxidized fatty acid (soybean oil, rapeseed oil, linseed oil), polyethylene acrylic acid, stearylated acrylate, emulsified asphalt or coal tar based resin, hydrophobic acrylic, or maleated polyethylene PE or polypropylene PP wax. 
     
     
         38 . The reinforcing mat of  claim 36  wherein the binder comprises styrene acrylate grafted with starch at slightly basic pH to near neutral pH and a cross-linker comprising, carbodiimide, aziridine, water dispersible epoxy, epoxy silane, water dispersible oxazoline, and polyamidoamide epichlorohydrin resin, and wherein the additive comprises, epoxidized fatty acid (soybean oil, rapeseed oil, linseed oil), polyethylene acrylic acid, stearylated acrylate, emulsified asphalt or coal tar based resin, hydrophobic acrylic, or maleated polyethylene PE or polypropylene PP waxes. 
     
     
         39 . The reinforcing mat of  claim 36  wherein the binder comprises acrylic acid modified polyvinyl acetate, and wherein the additive comprises, epoxidized fatty acid (soybean oil, rapeseed oil, linseed oil), polyethylene acrylic acid, stearylated acrylate, emulsified asphalt or coal tar based resin, hydrophobic acrylic, or maleated polyethylene PE or polypropylene PP wax. 
     
     
         40 . The reinforcing mat of  claim 36  wherein the binder comprises acrylic acid modified polyvinyl, and a cross-linker comprising, TACT triazine cross-linker, epoxy silane, zirconium ammonium carbonate, glyoxa, water dispersed blocked isocyanate, water dispersible epoxy, water dispersable isocyanate or polyamidoamide epichlorohydrin resin, and wherein the additive comprises, epoxidized fatty acid (soybean oil, rapeseed oil, linseed oil), polyethylene acrylic acid, stearylated acrylate, emulsified asphalt or coal tar based resin, hydrophobic acrylic, or maleated polyethylene PE or polypropylene PP wax. 
     
     
         41 . The reinforcing mat of  claim 36  wherein the binder comprises a polyacrylic acid blended polyol, and wherein the additive comprises, stearyl acrylate, stearyl melamine, epoxidized fatty acid based oil such as soybean or epoxy silane. 
     
     
         42 . The reinforcing mat of  claim 36 , wherein said bonded glass fibers are combined with molten asphalt at a temperature range of 150° C.-250° C. 
     
     
         43 . A method of making a building construction structure, comprising:
 imbedding the reinforcing mat of  claim 36  in a matrix composition, and hardening the matrix composition to provide a building construction structure reinforced by the reinforcing mat.   
     
     
         44 . The method of  claim 43  wherein the matrix composition comprises molten asphalt at a temperature in a range of 150° C-250° C. 
     
     
         45 . The method of  claim 43  wherein the matrix composition comprises gypsum or portland cement.